Light-emitting device

ABSTRACT

The reliability of a light-emitting device constituted by a combination of a TFT and a light-emitting element is to be improved. A light-emitting element is formed between a first substrate and a second substrate. The light-emitting device is formed over a first insulating layer made of an organic compound and a second insulating layer made of an inorganic insulating material containing nitrogen formed on the surface of the first insulating layer. In an outer circumferential part of a display area formed by the light-emitting element, a shield pattern surrounding the display area is formed by metal wiring on the second insulating layer, and the first substrate and the second substrate are fixed to each other with an adhesive resin formed in contact with the shield pattern.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a light-emitting device having alight-emitting element for emitting light by fluorescence orphosphorescence. Particularly, this invention relates to alight-emitting device having an active element such as an insulated gatetransistor or a thin film transistor, and a light-emitting elementconnected to the active element.

2. Description of the Related Art

A display device using liquid crystal, except for a reflection-typedisplay device using external light, usually has a structure in whichpanels holding liquid crystal between them and a light source arecombined to display an image. The liquid crystal display device isemployed as image display means in various electronic devices but it hasa disadvantage of a narrow view angle. On the other hand, a displaydevice using a light-emitting material which provideselectroluminescence has a wide view angle and excellent visibility.Therefore, this display device is noted as a next-generation displaydevice.

In a light-emitting element utilizing electroluminescence, electronsinjected from the cathode and positive holes injected from the anode arerecombined to form excitons in a layer made of a light-emitting material(light-emitting layer) and energy emitted at the time when the groundstate of the excitons is restored is taken out as light.Electroluminescence includes fluorescence and phosphorescence, which areunderstood as emission from a singlet state (fluorescence) and emissionfrom a triplet state (phosphorescence) in the excited state,respectively. Since the luminance due to the emission reaches a range ofseveral thousands to tens of thousands cd/m², it is considered possiblein principle to apply this electroluminescence to a display device orthe like.

As an example in which a thin film transistor (hereinafter referred toas TFT) and a light-emitting element are combined, a structure in whichan organic electroluminescence layer is formed via an insulating filmmade of silicon dioxide over a TFT using polycrystal silicon isdisclosed. A passivation layer having a tapered edge part on the anodeis situated below the organic electroluminescence layer. For thecathode, a material having a work function less than 4 eV is selected,and a magnesium alloy with a metal such as silver or aluminum is used(see Patent Literature 1).

It is known that organic compounds constituting the light-emittingelement and alkaline metals or alkaline-earth metals used as electrodesreact with water and oxygen and thus degrade. As a measure to preventdegradation due to moisture, a structure is known in which aplate-shaped protection casing for covering a display area is fixed withan adhesive or the like to a substrate over which the light-emittingelement is formed while a desiccant is arranged on the inner sidecovered with the protection casing (see Patent Literature 2, forexample).

Moreover, another structure is disclosed in which a display area isformed between a first substrate and a second substrate of differentmaterials, with a planarization film formed as a buffer layer between aseal for adhering the first and second substrates and one of thesubstrates. Since the planarization film as a buffer layer is formed,the influence of thermal stress is reduced and separation of the sealand the substrate is thus prevented (see Patent Literature 3, forexample).

The above-mentioned Patent Literatures are listed below.

Patent Literature 1: Japanese Publication of Laid-Open PatentApplication No. H8-241047

Patent Literature 2: Japanese Publication of Laid-Open PatentApplication No. H9-148066

Patent Literature 3: Japanese Publication of Laid-Open PatentApplication No. 2001-102166

However, even though the substrate on which the light-emitting device isformed and the protection casing or the sealing substrate arehermetically sealed by the seal, degradation due to moisture such as adark spot cannot be prevented. As the light-emitting element iselectrified and driven, the current within the device is converted toJoule heat and the device is heated. In this case, a defect occurs suchas a crack or breakage in the seal part or the coating at a bent part ofthe multilayer body due to a strain generated by the difference inthermal expansion coefficients between the constituent members, and itmay be considered that a progressive defect such as a dark spot occursfrom that part.

When forming a seal pattern for sealing around the display area formedfrom the light-emitting elements, in order to increase the adhesivenessand hermetic property of the seal are increased, the area required forthe seal around the pixel region is increased, thus enlarging aso-called frame region. If such a panel is incorporated in a machinewhich requires a display panel, the size and design of the equipment arelimited and its commercial value is lowered.

SUMMARY OF THE INVENTION

In view of the foregoing status of the art, it is an object of thepresent invention to improve the reliability of a light-emitting deviceconstituted by a combination of a TFT and a light-emitting element.

According to the present invention, there is provided a light-emittingdevice comprising a substrate on which a display area made up from alight-emitting element is formed, and a sealing substrate fixed on ashield pattern formed in an outer circumferential part of the displayarea, with a resin material formed along the shield pattern. The shieldpattern is made of a metal material and several such shield patterns maybe superimposed in a ring shape. As the resin material is formed incontact with the shield pattern, its adhesive strength is increased. Thepresent invention includes the following modes.

A light-emitting element is formed between a first substrate and asecond substrate. The light-emitting element is formed over a firstinsulating layer made of an organic compound and a second insulatinglayer made of an inorganic insulating material containing nitrogen andformed on the surface of the first insulating layer. In an outercircumferential part surrounding a display area formed by thelight-emitting device, a shield pattern surrounding the display area isformed by metal wiring on the second insulating layer, and the firstsubstrate and the second substrate are fixed to each other with anadhesive resin formed in contact with the shield pattern.

A light-emitting element is formed between a first substrate and asecond substrate. The light-emitting element is formed over a firstinsulating layer made of an organic compound and a second insulatinglayer made of an inorganic insulating material containing nitrogen andformed on the surface of the first insulating layer. In an outercircumferential part surrounding a display area formed by thelight-emitting device, a shield pattern surrounding the display area isformed by metal wiring on the inorganic insulating layer. Above thesecond insulating layer, a third insulating layer made of an organiccompound and a fourth insulating layer made of an inorganic insulatingmaterial containing nitrogen and formed to cover exposed top surface andlateral surfaces of the third insulating layer are formed. The topsurface of the metal wiring is arranged in an aperture of the thirdinsulating layer with its lateral surfaces covered with the fourthinsulating layer, and the first substrate and the second substrate arefixed to each other with an adhesive resin formed in contact with themetal wiring.

A light-emitting element is formed between a first substrate and asecond substrate. The light-emitting element is formed over a firstinsulating layer made of an organic compound and a second insulatinglayer made of an inorganic insulating material containing nitrogen andformed on the surface of the first insulating layer. In an outercircumferential part surrounding a display area formed by thelight-emitting device, a shield pattern surrounding the display area isformed by metal wiring on the inorganic insulating layer. Above thesecond insulating layer, a third insulating layer made of an organiccompound and a fourth insulating layer made of an inorganic insulatingmaterial containing nitrogen and formed to cover exposed top surface andlateral surfaces of the third insulating layer are formed. A pluralityof apertures are formed in the third insulating layer with its lateralsurfaces covered with the fourth insulating layer, and the top surfaceof the metal wiring is arranged in the apertures. The first substrateand the second substrate are fixed to each other with an adhesive resinformed in contact with the metal wiring.

A light-emitting element is formed between a first substrate and asecond substrate. The light-emitting element is formed over a firstinsulating layer made of an organic compound and a second insulatinglayer made of an inorganic insulating material containing nitrogen andformed on the surface of the first insulating layer. In an outercircumferential part surrounding a display area formed by thelight-emitting device, a shield pattern surrounding the display area isformed by metal wiring on the inorganic insulating layer. Above thesecond insulating layer, a third insulating layer made of an organiccompound and a fourth insulating layer made of an inorganic insulatingmaterial containing nitrogen and formed to cover exposed top surface andlateral surfaces of the third insulating layer are formed. The topsurface and lateral surfaces of the metal wiring are arranged in anaperture of the third insulating layer with its lateral surfaces coveredwith the fourth insulating layer, and the first substrate and the secondsubstrate are fixed to each other with an adhesive resin formed incontact with the metal wiring.

A light-emitting element is formed between a first substrate and asecond substrate. The light-emitting element is formed over a firstinsulating layer made of an organic compound and a second insulatinglayer made of an inorganic insulating material containing nitrogen andformed on the surface of the first insulating layer. In an outercircumferential part surrounding a display area formed by thelight-emitting device, a shield pattern surrounding the display area isformed by metal wiring on the inorganic insulating layer. Above thesecond insulating layer, a third insulating layer made of an organiccompound and a fourth insulating layer made of an inorganic insulatingmaterial containing nitrogen and formed to cover exposed top surface andlateral surfaces of the third insulating layer are formed. A pluralityof apertures are formed in the third insulating layer with its lateralsurfaces covered with the fourth insulating layer, and the top surfaceand lateral surfaces of the metal wiring are arranged in the apertures.The first substrate and the second substrate are fixed to each otherwith an adhesive resin formed in contact with the metal wiring.

In the above-described structures of the present invention, it isdesired that the inorganic insulating material is silicon nitrideprepared by an RF sputtering method. It is desired that the inorganicinsulating material has an oxygen content of 10 atom % or less and ahydrogen content of 10 atom % or less.

In the above-described structures of the present invention, the shieldpattern surrounding the display area is formed by metal wiring on theinorganic insulating layer. The third insulating layer made of anorganic compound is formed and the top surface or top and lateralsurfaces of the metal wiring are arranged in the aperture of the thirdinsulating layer. The first substrate and the second substrate are fixedto each other with the adhesive resin formed in contact with the metalwiring. Thus, the adhesive strength can be increased and the area of theshield pattern for sealing can be reduced. As a result, a so-calledframe region can be decreased.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view for explaining a structure of thelight-emitting device of the present invention.

FIG. 2 is a top view for explaining a structure of a pixel part of thelight-emitting device of the present invention.

FIG. 3 is an equivalent circuit diagram of the pixel.

FIG. 4 is an external view showing a substrate having constituentelements of the light-emitting device of the present invention.

FIG. 5 is a sectional view for explaining a structure of thelight-emitting device of the present invention.

FIGS. 6A to 6D are sectional views for explaining a preparation processfor the light-emitting device of the present invention.

FIGS. 7A to 7C are sectional views for explaining a preparation processfor the light-emitting device of the present invention.

FIGS. 8A and 8B are sectional views for explaining a preparation processfor the light-emitting device of the present invention.

FIGS. 9A and 9B are sectional views for explaining a preparation processfor the light-emitting device of the present invention.

FIG. 10 is a sectional view for explaining a preparation process for thelight-emitting device of the present invention.

FIG. 11 is a sectional view for explaining a preparation process for thelight-emitting device of the present invention.

FIGS. 12A, 12B and 12C are sectional views for explaining a preparationprocess for the light-emitting device of the present invention.

FIG. 13 is a sectional view for explaining a structure of thelight-emitting device of the present invention.

FIGS. 14A and 14B are sectional views for explaining a preparationprocess for the light-emitting device of the present invention.

FIG. 15 is a sectional view for explaining a structure of thelight-emitting device of the present invention.

FIGS. 16A and 16B are sectional views for explaining a structure of aninput terminal part and a sealing part.

FIGS. 17A and 17B are sectional views for explaining a structure of aninput terminal part and a sealing part.

FIGS. 18A and 18B are views for explaining an exemplary process forpreparing a semiconductor layer applied to a TFT constituting thelight-emitting device of the present invention.

FIGS. 19A to 19C are views for explaining an exemplary process forpreparing a semiconductor layer applied to a TFT constituting thelight-emitting device of the present invention.

FIGS. 20A to 20C are views for explaining an exemplary process forpreparing a semiconductor layer applied to a TFT constituting thelight-emitting device of the present invention.

FIG. 21 is a view for explaining an exemplary process for preparing asemiconductor layer applied to a TFT constituting the light-emittingdevice of the present invention.

FIGS. 22A to 22G show exemplary applications of the present invention.

FIGS. 23A and 23B are sectional views for explaining a structure of thelight-emitting device of the present invention.

FIGS. 24A and 24B are sectional views for explaining a structure of thelight-emitting device of the present invention.

FIGS. 25A and 25B are sectional views for explaining a structure of thelight-emitting device of the present invention.

FIGS. 26A and 26B are sectional views for explaining a structure of thelight-emitting device of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

A preferred embodiment of the present invention will now be described indetail with reference to the drawings. The present invention can becarried out in various many modes. It is readily understood by thoseskilled in the art that various changes and modifications can beeffected with respect to the forms and details of the present inventionwithout departing from the spirit and scope of the present invention.The present invention should not be interpreted as being limited to thecontents of the description of the following embodiment. Throughout theembodiment, the same elements are denoted by the same numerals.

FIG. 1 shows an example for explaining the structure of a light-emittingdevice of an active-matrix driving system. TFTs are provided in a pixelpart 302 and a driving circuit part 301 formed on the periphery of thepixel part 302. For a semiconductor layer forming a channel-formingregion of the TFT, amorphous silicon or polycrystal silicon can beselected. In the present invention, either one may be used.

For a substrate 101, a glass substrate or an organic resin substrate isemployed. Organic resin materials are lighter in weight than glassmaterials and therefore effectively act for reduction in weight of thelight-emitting apparatus itself. In preparing the light-emittingapparatus, organic resin materials such as polyimide, polyethyleneterephthalate (PET), polyethylene naphthalate (PEN), polyether sulfone(PES), aramid can be used. For the glass substrate, it is desired to usebarium borosilicate glass and alumino-borosilicate glass, which areexamples of non-alkaline glass. The thickness of the glass substrate is0.5 to 1.1 mm, but the thickness need be reduced for the purpose ofreducing the weight. Moreover, to reduce the weight, it is desired toemploy a glass substrate with a small specific gravity of 2.37 g/cm³.

In the structure shown in FIG. 1, an n-channel TFT 303 and a p-channelTFT 304 are formed in the driving circuit part 301, and a first TFT 305formed by an n-channel TFT, a fourth TFT 306 formed by a p-channel TFT,and a capacitor part 307 are formed in the pixel part 302. The fourthTFT 306 is connected with a light-emitting device 309.

These TFTs are constituted by semiconductor layers 103 to 106, a gateinsulating film 108 and gate electrodes 110 to 113 on a first inorganicinsulating layer 102 made of silicon nitride or silicon oxide-nitride.Over the gate electrodes, a second inorganic insulating layer 114 madeof silicon nitride or silicon oxynitride containing hydrogen is formedand it functions together with the first inorganic insulating layer 102as a protection film to prevent diffusion of and contamination byimpurity such as moisture and metals.

On the second inorganic insulating layer 114, a first organic insulatinglayer 115 made of a material selected from polyimide, polyamide,polyimideamide, acrylic and BCB is formed with a thickness of 0.5 to 1μm as a planarization film. The first organic insulating layer 115 isformed by baking after applying that organic compound by a spin coatmethod. The organic insulating material is hygroscopic and occludesmoisture. When the moisture is released, oxygen is supplied to theorganic compound of the light-emitting device above this first organicinsulating layer, thus causing degradation of the light-emittingelement. To prevent occlusion and release of moisture, a third inorganicinsulating layer 116 with a thickness of 50 to 200 nm is formed on thefirst organic insulating layer 115. The third inorganic insulating layer116 need be a fine film in consideration of adhesive and barrierproperties with the underlying layer. Preferably, the third inorganicinsulating layer 116 is made of an inorganic insulating materialselected from silicon nitride, silicon oxynitride, aluminum oxynitride,aluminum nitride and the like, formed by a sputtering method.

As for a silicon nitride film prepared by a sputtering method using onlynitrogen as a sputtering gas and using silicon as a target, a thicknessof 10 to 100 nm, preferably, 20 to 40 nm, suffices. Similarly, for analuminum oxynitride film prepared by a sputtering method, a thickness of40 nm or more is necessary.

The light-emitting device 309 is formed on the third inorganicinsulating layer 116. In the case of a structure such that emitted lightis radiated through the substrate 101, an ITO (indium tin oxide) layeris formed as an anode layer 126 on the third inorganic insulating layer116. For the purpose of flattening and reduction in resistance, zincoxide or gallium may be added to ITO. Wirings 117 to 125 are formedafter the anode layer 126 is formed, and the wiring 123 is superimposedon the anode layer 126 in the pixel part, thus forming electricalconnection.

A second organic insulating layer (partition layer) 128 separating eachpixel is made of a material selected from polyimide, polyamide,polyimideamide, acrylic and BCB. As these materials, thermosetting orphoto-curing materials can be applied. In forming the second organicinsulating layer (partition layer) 128, that the organic insulatingmaterial is formed with a thickness of 0.5 to 2 μm on the entire surfaceand then an aperture corresponding to the anode layer 126 is formedtherein. In this case, the aperture is formed to cover an end part ofthe anode layer 126 and its sidewall has an inclination of 35 to 45degrees. The second organic insulating layer (partition layer) 128 isformed not only in the pixel part 302 but also extended to the drivingcircuit part 301 to cover the wirings 117 to 124, thus functioning alsoas an interlayer insulating film.

The organic insulating material is hygroscopic and occludes moisture.When the moisture is released, the moisture is supplied to the organiccompound of the light-emitting element 309, thus causing degradation ofthe light-emitting element. To prevent occlusion and release ofmoisture, a fourth inorganic insulating layer 129 with a thickness of 10to 100 nm is formed on the second organic insulating layer 128. Thefourth inorganic insulating layer 129 is made of an inorganic insulatingmaterial containing nitrogen. Specifically, it is made of an inorganicinsulating material selected from silicon nitride, aluminum nitride, andaluminum oxynitride. The fourth inorganic insulating layer 129 is formedto cover the top surface and lateral surfaces of the second organicinsulating layer 128, and its end part superimposed on the anode layer126 is tapered.

The light-emitting device 309, is formed by the anode layer 128, acathode layer 131 containing an alkaline metal or alkaline-earth metal,and an organic compound layer 130 containing a light-emitting substanceformed between the anode and cathode layers. The organic compound layer130 containing a light-emitting substance is formed by a single layer ora plurality of stacked layers. These layers are called hole injectionlayer, hole transport layer, light-emitting layer, electron transportlayer, electron injection layer and the like, in accordance with theirrespective purposes and functions. These layers can be formed using oneof a low-molecular organic compound material, a medium-molecular organiccompound material and a high-molecular organic compound material, or aproper combination of these. A mixed layer made of an appropriatemixture of an electron transport material and a hole transport material,or a mixed junction such that a mixed region is formed on each junctioninterface may be formed.

The cathode layer 131 is made of an alkaline metal or alkaline-earthmetal having a small work function. A material containing magnesium(Mg), lithium (Li) or calcium (Ca) is used. Preferably, an electrodemade of MgAg (mixture of Mg and Ag at a ratio of Mg:Ag=10:1) may beused. Moreover, a MgAgAl electrode, a LiAl electrode, or a LiFAlelectrode may be used. Alternatively, the cathode layer 131 may beformed by a combination of fluoride of an alkaline metal oralkaline-earth metal and a low-resistance metal such as aluminum. Thecathode layer 131 is formed as a common electrode across a plurality ofpixels and is connected with the wiring 120 outside of the pixel part302 or between the pixel part 302 and the driving circuit part 301, thusbeing led to an external terminal.

Although not shown, a fifth inorganic insulating layer made of amaterial selected from silicon nitride, diamond-like carbon (DLC),aluminum oxide-nitride, aluminum oxide, aluminum nitride and the likemay be formed above the cathode layer 131. Particularly a DLC film isknown to have a high gas barrier property against oxygen, CO, CO₂, H₂Oand the like. It is desired to continuously form the fifth inorganicinsulating layer without opening to the atmosphere after forming thecathode layer 131. A buffer layer of silicon nitride may be formed belowthe fifth inorganic insulating layer to improve the adhesion.

Although not shown, either, a sixth inorganic insulating layer with athickness of 0.5 to 5 nm to allow flow of a tunnel current may be formedat the interface between the anode layer 126 and the organic compoundlayer 130 containing the light-emitting material. This is effective inpreventing occurrence of a short circuit due to unevenness on thesurface of the anode and in restraining diffusion of the alkaline metalor the like used in the cathode to the lower layer.

In FIG. 1, the first TFT 305 has a multi-gate structure and is providedwith a lightly doped drain (LDD) to reduce an OFF-state current. Thefourth TFT 306 is provided with an LDD to overlap the gate electrode.The TFT using polycrystal silicon shows a high operating speed andtherefore tends to be degraded by a hot carrier effect. Therefore,forming TFTs of different structures depending on the functions (TFT forswitching which has a sufficiently low OFF-state current and TFT forcurrent control which is durable to hot carrier injection) within apixel, as shown in FIG. 1, is very effective in preparing alight-emitting device which has high reliability and enablessatisfactory image display (having high performance). FIG. 2 is a topview of this pixel part. FIG. 2 shows the structure for substantiallyone pixel, in which the first TFT 305, a second TFT 311, a third TFT312, the fourth TFT 306 and the capacitor part 307 are provided. FIG. 3is an equivalent circuit diagram thereof.

Of course, the pixel structure shown here is only an example and is notan essential requirement for constituting the present invention.

The circuit structure of the driving circuit part 301 differs between agate signal-side driving circuit and a data signal-side driving circuit,but this difference will not be described here. The n-channel TFT 303and the p-channel TFT 304 are connected with the wirings 118, 119, and ashift register, a latched circuit, a buffer circuit and the like can beformed using these TFTs.

An input terminal part 308 is formed by a wiring formed from the samelayer as the gate electrode or a wiring formed on the third inorganicinsulating layer 116. In the example shown in FIG. 1, the input terminalpart is formed from the same layer as the gate electrode and isconstituted by conductive layers 109 and 127. The conductive layer 127is formed simultaneously with the anode layer 126 and is made of anoxide conductive material. Actually, a part of exposed surface iscovered with this oxide conductive material to prevent increase insurface resistance due to oxidation.

The second organic insulating layer 128 formed in the pixel part 302extends over the driving circuit part 301. On an outer circumferentialpart of the substrate 101, a shield pattern 140 made from the same layeras the wirings 117 to 125 formed on the third inorganic insulating layeris provided. The metal wiring 140 is maintained at a constant electricpotential, and typically, it is preferable that the metal wiring 140 isgrounded. The second organic insulating layer 128 extends to the regionwhere the shield pattern is formed, and an aperture corresponding to thearrangement of the metal wiring 140 is formed therein. A plurality ofsuch apertures may be formed in accordance with the shield pattern. Theshield pattern may be partly overlapped with the driving circuit part301 and the wiring 117 connecting the driving circuit part 301 with theinput terminal, and this reduces the area of the frame region(peripheral region of the pixel part) of the light-emitting device.

An adhesive resin 133 is filled in this aperture and its periphery, anda sealing substrate 134 is fixed thereto. For the sealing substrate 134,metals such as stainless steel and aluminum can be used. A glasssubstrate or the like may also be used. Inside the space surrounded bythe adhesive resin 133 and the sealing substrate 134, a desiccant 135such as barium oxide may be sealed to prevent degradation due tomoisture. For the sealing substrate, an organic resin material having athickness of approximately 30 to 120 μm may be used to provideflexibility. On the surface of the sealing substrate, a coating made ofan inorganic insulating material such as DLC or silicon nitride may beformed as a gas barrier layer. An exemplary material used for the sealpattern is an epoxy-based adhesive, and by covering its lateral partswith a coating made of an inorganic insulating material, vaporpenetration through that part can be prevented.

As the adhesive resin 133, an ultraviolet-curing acrylic resin or acationic ultraviolet-curing epoxy resin can be used.

The adhesive strength between the sealing substrate 134 and thesubstrate 101 having the light-emitting element 309 formed thereon isincreased by the aperture formed in the second organic insulating layer128 and the fourth inorganic insulating layer 129 on the shield pattern.The adhesive resin 133 is in contact with the fourth inorganicinsulating layer 129 or the metal wiring 140 and adheres at that part.The recessed and protruding shape formed by the aperture relaxes thestress at the time when the adhesive resin 133 is cured, and thusimproves the adhesion. To increase the adhesiveness with the adhesiveresin 133, a titanium nitride may be formed on the outermost surface ofthe metal wiring 140.

FIGS. 16A and 16B show another form in which the substrate 101 havingthe light-emitting device 309 formed thereon and a sealing substrate 135are fixed to each other. In FIG. 16A, a contact hole is formed in thethird inorganic insulating layer 116, the first organic insulating layer115 and the second inorganic insulating layer 114, and a recess part 136is formed in the metal wiring 140. This recess part 136 may be formedover the entire circumference along the metal wiring 140 or may bediscretely formed. Again, this recessed and protruding shape relaxes thestress of the adhesive resin 133 and can provide a high adhesivestrength.

As shown in FIG. 16B, the metal wiring 140 may be only one. In thiscase, the recessed and protruding shape formed by the second organicinsulating layer 128 and the fourth inorganic layer 129 may be preparedon the wiring. Such a structure, too, can provide similar effects.

FIG. 17A shows a structure in which the adhesive resin 133 contacts thetop surface and lateral surfaces of the metal wiring 140. FIG. 17B showsthe details thereof. For the metal wiring 140, a material containingaluminum as a principal component is used as a low-resistance material.However, aluminum tends to corrode, and when in contact with silicon, itdiffuses even at 200° C. or less. Therefore, a multilayer structure isapplied to the metal wiring, as shown in FIG. 17B. In a typicalstructure, a first metal layer 140 a and a third metal layer 140 c aremade of a refractory metal or an alloy or silicide containing thatmetal, and a second metal layer 140 b is made of a low-resistance metalsuch as aluminum. For example, the first metal layer 140 a can be madeof titanium with a thickness of 100 nm and the second metal layer 140 bcan be made of aluminum with a thickness of 300 nm, while the thirdmetal layer 140 c can be made of titanium nitride with a thickness of150 nm. The lateral end surface of the aluminum of the second metallayer 140 b is oxidized. Actually, the adhesive resin 133 and aluminumoxide contact each other to increase the adhesive strength.

As shown in FIG. 1, the first inorganic insulating layer 102 is formedbelow the semiconductor layers 105, 106 (on the side of the substrate101). On the other hand, the second inorganic insulating layer 114 isformed on the semiconductor layers 105, 106. The third inorganicinsulating layer 116 is formed below the light-emitting element 309. Afifth inorganic insulating layer 132 may be formed above thelight-emitting device 309. Moreover, the fourth inorganic insulatinglayer 129 is formed between them. All of these are made of inorganicinsulating materials. The light-emitting element 309 is formed in thisstructure.

The substrate 101 and the light-emitting element 309 are considered tobe contamination source of alkaline metals such as sodium to the firstTFT 305 and the fourth TFT 306, but this can be prevented by surroundingthe TFTs by the first inorganic insulating layer 102 and the secondinorganic insulating layer 114. Meanwhile, the light-emitting device 309is most vulnerable to oxygen and moisture. To prevent oxygen andmoisture from contacting the light-emitting element 309, the thirdinorganic insulating layer 116, the fourth inorganic insulating layer129 and the fifth inorganic insulating layer 132 are formed usinginorganic insulating materials, thus preventing contamination from thelight-emitting device 309. These layers also have a function to preventdischarge of alkaline metal elements held in the light-emitting element309 toward the TFTs.

FIG. 4 shows an appearance of a substrate having the constituentelements of the light-emitting apparatus described with reference toFIG. 1. The pixel part 302, gate signal-side driving circuits 301 a, 301b, a data signal-side driving circuit 301 c, a cathode layer connectingpart 310, the input/output terminal part 308, the wiring or wiring group117 are provided on the substrate 101. The metal wiring 140 forming ashield pattern may be partly overlapped with the gate signal-sidedriving circuit 301 a, 301 b, the data signal-side driving circuit 301 cand the wiring or wiring group 117 which connects this driving circuitpart with the input terminal. The ring-shaped pattern formed by themetal wiring 140 may be a single pattern or may be a multiple patternusing a plurality of wirings. The pattern may be a continuous linearpattern, as shown in an inserted view (A) of FIG. 4, or may besuperimposed discontinuous dotted-line patterns, as shown in an insertedview (B) of FIG. 4. This enables reduction in area of the frame region(peripheral region of the pixel part) of the light-emitting device. AnFPC 136 is fixed at an external input terminal part.

FIG. 5 shows a sectional structure along a line B-B′ at a lateral endpart of the light-emitting device shown in FIG. 4. In this part, too, ashield pattern made from the metal wiring 140 is provided. The secondorganic insulating layer 128 extends to the region where the shieldpattern is formed, and an aperture corresponding to the arrangement ofthe metal wiring 140 is formed therein. A plurality of such aperturesmay be formed in accordance with the shield pattern, as shown in FIG. 5.The adhesive resin 133 is filled in the aperture and its periphery andthe sealing substrate 134 is fixed thereto. A recess part may be formedin the metal wiring 140. Again, this recessed shape relaxes the stressof the adhesive resin 133 and can provide a high adhesive strength.

By thus combining the TFT and the light-emitting element to form thepixel part, the light-emitting device can be completed. In such alight-emitting device, a driving circuit can also be formed on the samesubstrate by using a TFT. When the semiconductor film, the gateinsulating film and the gate electrode, as the principal constituentelements of the TFT, are surrounded by the blocking layer and theprotection film which are made of silicon nitride or silicon oxynitridefrom below and over these constituent elements, as shown in FIG. 1, astructure is provided in which contamination due to alkaline metals andorganic substances is prevented. Meanwhile, the light-emitting elementpartly contains an alkaline metal and is surrounded by the protectionfilm made of silicon nitride, silicon oxide-nitride or a DCL film, andthe gas barrier layer made from an insulating film containing siliconnitride or carbon as a principal component, thus having a structure inwhich penetration of oxygen and moisture from outside is prevented.

EXAMPLES Example 1

Next, the process of manufacturing the light emitting device shown inthe FIG. 1 is described in detail with reference to the figures.

In FIG. 6A, the substrate 101 may be one of a glass substrate, a quartzsubstrate, a ceramic substrate or the like. The substrate 101 maycomprise a silicon substrate, a metal substrate or a stainless substratewith an insulation film formed thereon. A plastic substrate having heatresistance bearable to the processing temperature of the example may beused.

A first inorganic insulation layer 102 comprising an insulation filmsuch as a silicon oxide film, a silicon nitride film or a siliconoxynitride film (SiO_(x)N_(y)) is formed on the substrate 101. A typicalexample has two-layer construction, in which the first siliconoxynitride film of 50 nm thickness is formed using SiH₄, NH₃ and N₂O asa reaction gas, and the second silicon oxynitride film of 100 nmthickness is formed on the first film, using SiH₄ and N₂O as a reactiongas.

The semiconductor layer functioning as an active layer can be obtainedby crystallizing the amorphous semiconductor film formed on the firstinorganic insulation layer 102. The amorphous semiconductor film isformed with thickness of 30 to 60 nm, and crystallized by heating, orirradiating laser beams. There is no restriction on the material of theamorphous semiconductor film, however, silicon or silicon germanium(Si_(1−x)Ge_(x);0<x<1. Representative value for x is 0.001 to 0.05)alloy may be preferably used.

In a representative example, the amorphous silicon film of 54 nmthickness is formed by the plasma CVD method using SiH₄ gas. Incrystallization, a pulse oscillating or a continuous oscillating excimerlaser, or a YAG laser, a YVO₄ laser or a YLF laser can be used. Whenusing one of a YAG laser, a YVO₄ laser or a YLF laser, the secondharmonic to the fourth harmonic can be used. When using one of theselasers, the laser beam irradiated from the laser oscillator can belinearly collected by an optical system to irradiate on thesemiconductor film. The condition of the crystallization can be selectedby the operator appropriately.

For crystallization, certain metal element such as nickel that can serveas a catalyst for the crystallization of the semiconductor, can beadded. An exemplary process of crystallization is; holding a solutioncontaining nickel on the amorphous silicon film, dehydrogenating (500°C. for one hour), crystallizing at 550° C. for four hours, thenirradiating the second harmonic of a continuous wave laser selected froman excimer laser, a YAG laser, a YVO₄ laser, or a YLF laser, in order toimprove the crystallization.

The resulting crystalline semiconductor film is etched in a desired formby photolithography using a photo mask (1) to form semiconductor layers103 to 107 separated like islands. After the formation of thesemiconductor layers 103 to 107, P-type impurity elements can be dopedto control the threshold voltage of the n-channel TFT. P-type impurityelements, with respect to the semiconductor, include the elementsbelonging to Group 13 in the periodic table, such as boron (B), aluminum(Al) and garium (Ga).

Next, as shown in the FIG. 6B, the gate insulation film 108 covering thesemiconductor layers 103 to 107 separated like islands is formed. Thegate insulation film 108 of 40 to 150 nm thickness is formed frominsulation film containing silicon by the plasma CVD method or thesputtering using inorganic insulation materials such as silicon oxide orsilicon oxynitride. This gate insulation layer can use insulation filmcontaining silicon as a single layer construction or a laminateconstruction.

Note that, in the case where a silicon oxide film is used as the gateinsulation film 108, the gate insulating film may be formed such that:TEOS (tetraethyl orthosilicate) and O₂ are mixed by the plasma CVDmethod; a reaction pressure of 40 Pa and a substrate temperature of 300to 400° C. are set; and an electric discharge is made with a highfrequency (13.56 MHz) power density of 0.5 to 0.8 W/cm² to form thesilicon oxide film having a thickness of 115 nm.

A first conductive film 10 of 10 to 50 nm thickness comprising tantalumnitride (TaN), and a second conductive film 11 of 100 to 400 nmthickness comprising tungsten (W) are laminated on the gate insulationfilm 108 in order to form a gate electrode. Other conductive materialfor gate electrode may be selected from Ta, W, Ti, Mo, Al, Cu, or analloy or a compound material having one of above elements as a maincomponent. Also, a semiconductor film including a poly-crystallinesilicon film doped with an impurity element such as phosphorus may beused. Furthermore, a combination of the first conductive film of atantalum film (Ta) and the second conductive film of a W film, acombination of the first conductive film of a tantalum nitride (TaN)film and the second conductive film of a Al film, or a combination ofthe first conductive film of a tantalum nitride (TaN) film, and thesecond conductive film of Cu film are also accepted.

Next, as shown in the FIG. 6C, a mask 12 on which gate electrodepatterns are formed by photolithography is formed by using a photo mask(2). After that, the first etching is performed with dry-etching. Foretching method, for example, ICP (Inductively Coupled Plasma) etching isapplicable. There is no restriction on the etching gas, however, CF₄,Cl₂ and O₂ are used for etching of W and TaN. In the first etching,predetermined biasing voltage is applied to the substrate to makeinclination angle of 15 to 50 degrees on the side surface of the formedelectrode patterns 13 to 17. A region of the insulation film formed asthe gate insulation film in which 10 to 30 nm of thickness is reduced isformed by the first etching.

Next, as shown in the FIG. 6D, anisotropic etching is performed on the Wfilm using SF₆, Cl₂ and O₂ as etching gases, and applying predeterminedbiasing voltage to the substrate, changing the etching condition to thesecond etching condition. The gate electrodes 110 to 113 and the wiring109 of an input terminal are thus formed. After that, the mask 12 isremoved. A region of the insulation film surface formed as the gateinsulation film in which 10 to 30 nm of thickness is further reduced isformed by the second etching.

After formation of the gate electrode, a first doping is performed asshown in the FIG. 7A to form first n-type impurity regions 18 to 22 inthe semiconductor layer. These first n-type impurity regions are formedin a self-aligned manner using the gate electrode as a mask. The dopingcondition can be set appropriately, using 5% PH₃ diluted with hydrogen,and injecting 6×10¹³/cm² dose at 50 kV.

Next, as shown in the FIG. 7B, a mask 23 is formed by using a photo-mask(3) and a second doping is performed by photolithography. The seconddoping uses 5% PH₃ diluted with hydrogen, and injects 3×10¹⁵/cm² dose at65 kV to form second n-type impurity regions 24, 25 and a third n-typeimpurity region 26. The second n-type impurity region 24 formed in theoutside of the gate electrode and the third n-type impurity region 26formed to be overlapped with the gate electrode in the semiconductorlayer 103 are formed in a self-aligned manner using the gate electrodeas a mask. In the semiconductor layer 105, the second n-type impurityregion 25 is formed by the mask 23.

Next, as shown in the FIG. 7C, a mask 27 is formed by using a photo-mask(4), and a third doping is performed by photolithography. The thirddoping uses 5% B₂H₆ diluted with hydrogen, and injecting 2×10¹⁶/cm² doseat 80 kV to form a p-type impurity regions 28 to 30 in the semiconductorlayers 104, 106 and 107.

As the result of the above processes, the impurity regions having eithern-type conductivity or p-type conductivity are formed in eachsemiconductor layer, respectively. As shown in the FIG. 8A, in thesemiconductor layer 103, the second n-type impurity region 24 acts as asource or drain region, and the third n-type impurity region 26 acts asa LDD region. In the semiconductor layer 104, the p-type impurity region28 acts as a source or drain region. In the semiconductor layer 105, thesecond n-type impurity region 25 acts as a source or drain region, andthe first n-type impurity region 20 acts as a LDD region. In thesemiconductor layer 106, the p-type impurity region 29 acts as a sourceor a drain region.

Next, the second inorganic insulation layer 114 covering almost all thesurface is formed. The second inorganic insulation layer 114 of 100 to200 nm thickness is formed using the plasma CVD or the sputtering, withan inorganic insulation material containing silicon and hydrogen. Thepreferred example is an oxynitride silicon film of 150 nm thicknessformed by the plasma CVD.

After formation of the second inorganic insulation layer 114, eachimpurity element added to each semiconductor layer is activated.Activation is performed by heating in a furnace anneal or a clean oven.The temperature is 400 to 700° C., typically, 410 to 500° C. of nitrogenatmosphere. The impurity regions may be activated by laser anneal, orrapid thermal anneal (RTA), as well.

Next, as shown in the FIG. 8B, the first organic insulation layer 115with a thickness of 0.5 to 1 μm is formed on the second inorganicinsulation layer 114. Thermosetting acrylic material can be used as theorganic insulation layer, which is spin-coated, then calcined at 250° C.to form planarized film. On this film, the third inorganic insulationlayer 116 of 50 to 100 nm thickness is formed.

When forming the third inorganic insulation layer 116, the substratehaving the second inorganic insulation layer 114 formed thereon isheated at 80 to 200° C. under reduced pressure for dehydration. Anexemplary material suitable for the third inorganic insulation layer 116is the silicon nitride film formed by the sputtering using silicon as atarget. Conditions for forming a film can be selected appropriately.Preferably, nitrogen (N₂) or mix of nitrogen and argon is applied assputtering gas by RF power for sputtering. The substrate may beprocessed in atmosphere temperature, without heating. An exemplaryprocess shows the silicon nitride film formed by applying RF power(13.56 MHz) using silicon as a target, and using only nitrogen gas forsputtering. The targets are silicon with boron added by 1 to 2 Ωsq. andRF power (13.56 MHz) with 0.4 Pa, 800 W by applying only nitrogen gas.The target has a diameter of 152.4 mm.

Next, as shown in the FIG. 9A, mask patterns are formed byphotolithography by using a photo-mask (5), then a contact hole 30 andan opening 31 of the input terminal are formed by dry-etching. Theconditions of the dry-etching are as follows; etching the thirdinorganic insulation layer 116 and the first organic insulation layer115 using CF₄, O₂ and He, then, etching the second inorganic insulationlayer 114 and the gate insulation layer 108 using CHF₃.

Subsequently, ITO with thickness of 30 to 120 nm is formed by sputteringmethod, a photo-mask (6) is used to form a predetermined pattern byphotolithography. Herewith, an anode layer 126 of the light emittingelement is formed, and a ITO film 127 over wirings on the input terminalis formed.

After that, as shown in the FIG. 9B, wirings and pixel electrodes areformed using Al, Ti, Mo or W. A photo-mask (7) is used for formingwirings. For example, a laminated film of a Ti film of 50 to 250 nmthickness and Al and Ti alloy film of 300 to 500 nm thickness may beused. The wirings 117 to 125 are thus formed.

Next, as shown in the FIG. 10, the second organic insulation layer 128is formed. This layer is formed with an acrylic material similar to thefirst organic insulation layer 115. Then, openings are formed on theanode layer 126, the connection with the cathode layer 310, and theinput terminal by using a photo-mask (8). The second organic insulationlayer 128 is formed so as to cover the end of the anode layer 126, andits side surface has an inclination angle of 35 to 45 degree.

The organic insulation material is hygroscopic and occludes moisture. Inorder to prevent the occlusion and release of moisture, a fourthinorganic insulation layer 129 of 10 to 100 nm thickness is formed onthe second organic insulation layer 128. The fourth inorganic insulationlayer 129 is formed with inorganic insulation material consisting of anitride. The fourth inorganic insulation layer 129 is formed with asilicon nitride film manufactured by the sputtering. The applicable filmis similar to that for the third inorganic insulation layer 116. Thefourth inorganic insulation layer 129 covers the upper surface and theside surface of the second organic insulation layer 128, with a taperedend overlapping on the anode layer 126.

An opening 310 is a connection part of a cathode layer and a wiring 120of a light emitting device 309. The opening 310 is provided in thevicinity of the pixel portion, when a problem about the resistance ofthe cathode layer occurs, the opening 310 can be provided in pluralparts.

Subsequently, an organic compound layer 130 containing a light emittingmaterial, a cathode layer 131 and the like are formed as shown in theFIG. 11, a light emitting device shown in the FIG. 1 can be manufacturedby adhering a sealing plate. A light emitting device can be manufacturedby using 9 photomasks in accordance with the above steps.

Note that in this example, the light emitting element 309 provided bylaminating in order of the anode layer 126, the organic compound layer130, and the cathode 131 from the third inorganic insulation layer 116is exemplified, but the invention is not limited to this structure, thelight emitting element also can be laminated in inverse order thereoffrom the third inorganic insulation layer 116.

Example 2

In this example, preparation of the light-emitting device through adifferent process from that of Example 1 will be described withreference to the drawings.

First, the layers up to the first organic insulating layer 115 and thethird inorganic insulating layer 116 shown in FIG. 8B are formed by aprocess similar to that of Example 1. Then, an ITO 32 is formed on thethird inorganic insulating layer 116 as shown in FIG. 12A.

After that, the ITO is etched to form the anode layer 126, and then acontact hole 30 is formed, as shown in FIG. 12B. This etching processingenables simultaneous exposure of a terminal 109 in the input terminalpart. Then, wirings or pixel electrodes are formed using Al, Ti, Mo, Wand the like, as shown in FIG. 12C. The wirings may be formed similarlyto those of Example 1. A wiring 141 can be applied on the terminal 109and this structure enables reduction in resistance of the inputterminal.

Moreover, the second organic insulating layer 128 is formed as shown inFIG. 13. This layer is made of an acrylic resin material, similarly tothe first organic insulating layer 115. Then, openings are formed on theanode layer 126, the connection with the cathode layer 310, and theinput terminal. The second organic insulating layer 128 is formed tocover an end part of the anode layer 126 and its sidewall has aninclination of 35 to 45 degrees.

On the second organic insulating layer 128, the fourth inorganicinsulating layer 129 with a thickness of 10 to 100 nm is formed. Thefourth inorganic insulating layer 129 is made of an inorganic insulatingmaterial comprising nitride. For the fourth inorganic insulating layer129, a silicon nitride film prepared by a sputtering method is used. Asilicon nitride film similar to that of the third inorganic insulatinglayer 116 is used. The fourth inorganic insulating layer 129 is formedto cover the top surface and lateral surfaces of the second organicinsulating layer 128, and its end part superimposed on the anode layer126 is tapered.

After that, the organic compound layer containing a light-emittingmaterial, the cathode layer, the shield pattern and the like are formedand the sealing substrate is fixed. Thus, the light-emitting device canbe prepared. Also in the light-emitting device prepared in this manner,the n-channel TFT 303 and the p-channel TFT 304 are formed in thedriving circuit part 301, and the first TFT 305, the fourth TFT 306 andthe capacitor part 307 are formed in the pixel part 302.

Example 3

In this example, preparation of the light-emitting device through adifferent process from that of Example 1 will be described withreference to the drawings.

First, the layers up to the first organic insulating layer 115 and thethird inorganic insulating layer 116 shown in FIG. 8B are formed by aprocess similar to that of Example 1. Then, a contact hole 30 is formedas shown in FIG. 14A. This etching processing enables simultaneousexposure of a terminal 109 in the input terminal part.

Then, wirings and pixel electrodes are formed using Al, Ti, Mo, W andthe like, as shown in FIG. 14B. The wirings may be formed similarly tothose of Example 1. A wiring 141 can be applied on the terminal 109 andthis structure enables reduction in resistance of the input terminal.

After that, an ITO film is formed and etched to form the anode layer126. In accordance with this process order, the ITO 127 can be appliedon the wiring 141 of the input terminal part and increase in contactresistance with the FPC can be prevented.

Moreover, the second organic insulating layer 128 is formed as shown inFIG. 15. This layer is made of an acrylic material, similarly to thefirst organic insulating layer 115. Then, openings are formed on theanode layer 126, the connection with the cathode layer 310, and theinput terminal. The second organic insulating layer 128 is formed tocover an end part of the anode layer 126 and its sidewall has aninclination of 35 to 45 degrees.

On the second organic insulating layer 128, the fourth inorganicinsulating layer 129 with a thickness of 10 to 100 nm is formed. Thefourth inorganic insulating layer 129 is made of an inorganic insulatingmaterial comprising nitride. For the fourth inorganic insulating layer129, a silicon nitride film prepared by a sputtering method is used. Asilicon nitride film similar to that of the third inorganic insulatinglayer 116 is used. The fourth inorganic insulating layer 129 is formedto cover the top surface and lateral surfaces of the second organicinsulating layer 128, and its end part superimposed on the anode layer126 is tapered.

After that, the organic compound layer containing a light-emittingsubstance, the cathode layer, the shield pattern and the like are formedand the sealing substrate is fixed. Thus, the light-emitting device canbe prepared. Also in the light-emitting device prepared in this manner,the n-channel TFT 303 and the p-channel TFT 304 are formed in thedriving circuit part 301, and the first TFT 305, the fourth TFT 306 andthe capacitor part 307 are formed in the pixel part 302.

Example 4

An example of manufacturing process of the semiconductor layer to beapplied to the TFT in the examples 1 to 3 will be described withreference to the FIG. 18. In this example, continuous wave laser beamsscan the amorphous silicon film formed on the insulation surface tocrystallize the same.

A barrier layer 402 comprising a silicon oxynitride film of 100 nmthickness is formed on a glass substrate 401, as shown in the FIG. 18A.On the barrier layer 402, an amorphous silicon film 403 of 54 nmthickness is formed by the plasma CVD method.

The laser beams are the continuous beams irradiated with continuousoscillation from a Nd:YVO₄ laser oscillator, and the second harmonic(532 nm) obtained by a wavelength conversion element is irradiated. Thecontinuous wave laser beams are collected in an oblong shape by anoptical system, and by moving relative positions of the substrate 401 tothe point from which the laser irradiate the beam 405, the amorphoussilicon film 403 is crystallized to form a crystalline silicon film 404.F20 cylindrical lens can be adopted as the optical system, whichtransforms the laser beam with a diameter of 2.5 mm into an oblong shapewith long axis of 2.5 mm and short axis of 20 μm on the irradiatedsurface.

Of course, other laser oscillator may equally be applicable. As acontinuous solid-state laser oscillator, a laser oscillator using acrystal such as YAG, YVO₄, YLF or YAlO₃, doped with Cr, Nd, Er, Ho, Ce,Co, Ti or Tm may be applicable.

When using the second higher harmonic (532 nm) of the Nd:YVO₄ laseroscillator, the wavelength transmits the glass substrate 401 and thebarrier layer 402. Therefore, the laser beam 406 may be irradiated fromthe glass substrate 401 side, as shown in the FIG. 18B.

Crystallization proceeds from the area on which the laser beam 405 isirradiated, to form a crystalline silicon film 404. The laser beam maybe scanned in either one direction or backwards and forwards. Whenscanning forwards and backwards, the laser energy density may be changedfor each scanning to make step-wise crystallization. The scanning mayhave dehydrogenation effect as well, which is often necessary when anamorphous silicon film is to be crystallized. In that case, the firstscanning may be performed at lower energy density, then, afterdehydrogenation, the second scanning may be performed at higher energydensity to complete the crystallization. Such process can also provide acrystalline semiconductor film in which crystal grains extend in thedirection of laser beam scanning. After these processes, semiconductorlayers are separated like islands, which can be applied to the example1.

The construction shown in this example is only exemplary. Other laseroscillator and other optic system and combination thereof may beapplicable as long as similar effect can be obtained.

Example 5

An example of manufacturing process of the semiconductor layer to beapplied to the TFT in the examples 1 to 3 will be described withreference to the FIG. 19. In this example, an amorphous silicon filmformed on the insulation surface is crystallized in advance, then,expanding the size of the crystal grains by continuous oscillating laserbeams.

As shown in the FIG. 19A, a blocking layer 502 and an amorphous siliconfilm 503 are formed on a glass substrate 501 as is in the example 1. Thenickel acetate 5 ppm solution is spin-coated to form a catalyst elementcontaining layer 504 in order to add Ni as a metal element to lower thecrystallization temperature and facilitate the crystallization.

The amorphous silicon film is crystallized by heating at 580° C. forfour hours, as shown in the FIG. 19B. Silicide is formed and diffused inthe amorphous silicon film by the effect of Ni, and the crystal growssimultaneously. The resultant crystalline silicon film 506 consists ofbar-shaped or needle-shaped crystals, each of which grows in specificdirection when seen from a macroscopic viewpoint, thus the crystals areuniform. Further, it is orientated to the {110} surface.

As shown in the FIG. 19C, scanning by continuous wave laser beam 508 isperformed to improve the quality of the crystallization of thecrystalline silicon film 506. By irradiating the laser beam, thecrystalline silicon film melts and re-crystallize. In thisre-crystallization, the crystal grains extend in the scanning directionof the laser beam. In this case, since a crystalline silicon film whichcrystal planes are aligned is formed in advance, formation of crystalgrains with different crystal planes and dislocation is prevented. Afterthese processes, semiconductor layers are separated like islands, whichcan be applied to the examples 1 to 3.

Example 6

An example of manufacturing process of the semiconductor layer which canbe applied to the TFT in the example 1 will be described with referenceto the FIG. 20.

As shown in the FIG. 20A, a blocking layer 512 and an amorphous siliconfilm 513 are formed on a glass substrate 511 as is in the example 3. Onthis film, a silicon oxide film of 100 nm thickness is formed as a maskinsulation film 514 by the plasma CVD, and an opening 515 is provided.The nickel acetate 5 ppm solution is spin-coated in order to add Ni as acatalyst element. Ni contacts the amorphous silicon film at the opening515.

Next, as shown in the FIG. 20B, the amorphous silicon film iscrystallized by heating at 580° C. for four hours. By the effect of thecatalyst element, the crystals grow from the opening 515 in a directionparallel to the surface of the substrate. The resultant crystallinesilicon film 517 consists of bar-shaped or needle-shaped crystals, eachof which grows in specific direction when seen from a macroscopicviewpoint, thus the crystals are uniform. Also, it is oriented in aspecific direction.

After heating, the mask insulation film 514 is removed by etching toobtain a crystalline silicon film 517 as shown in the FIG. 20C. Afterthese processes, semiconductor layers are separated like islands, whichcan be applied to the example 1.

Example 7

In the example 5 or 6, after the formation of the crystalline siliconfilm 517, a process can be added to remove the catalyst elementremaining in the film with concentration of 10¹⁹ atoms/cm³ or more, bygettering.

As shown in the FIG. 21, a barrier layer 509 comprising thin siliconoxide film is formed on the crystalline silicon film 507, then anamorphous silicon film added with argon or phosphorus of 1×10²⁰atoms/cm³ to 1×10²¹ atoms/cm³ is formed by the sputtering, as agettering site 510.

The Ni which is added as a catalyst element can be segregated to thegettering site 510, by heating at 600° C. for 12 hours in a furnaceanneal, or by heating at 650 to 800° C. for 30 to 60 minutes with RTAusing lamp light or heated gas. This process reduces the concentrationof the catalyst element in the crystalline silicon film 507 to 10¹⁷atoms/cm³ or less.

The gettering under similar condition is effective for the crystallinesilicon film formed in the example 4. The minute amount of the metalelement contained in the crystalline silicon film formed by irradiatinglaser beams to the amorphous silicon film can be removed by thisgettering.

Example 8

FIGS. 23A and 23B and FIGS. 24A and 24B show different structures of thepixel part 302 in the light-emitting device of the active-matrix drivingsystem of the present invention described in Example 1. In thesestructures, a light shielding film is provided in the pixel part, andthe regions except where the light-emitting element 309 is formed arecovered with the light shielding film. The effect of the light shieldingfilm is to prevent externally incident light from being scattered by thewiring and electrodes, thus enabling display of a visually sharp image.

FIG. 23A shows a structure in which a light shielding layer 2401 isprovided between the second inorganic insulating layer 114 and the firstorganic insulating layer 115. As the light shielding layer is providedbelow the first organic insulating layer 115 for the purpose offlattening, the flatness of the pixel part is secured and light emittedfrom the light-emitting element 309 can be securely prevented from beingincident on the TFT side. This structure is effective in thelight-emitting device in which light emitted from the light-emittingelement 309 is radiated to the substrate side. In a region where lightis radiated, an aperture is formed in the light shielding layer 2401.

FIG. 23B shows a structure in which a light shielding layer 2402 isprovided on the third inorganic insulating layer 116. The wirings 121 to125 are provided on the light shielding layer 2402. Also this structureis effective in the light-emitting device in which light emitted fromthe light-emitting element 309 is radiated to the substrate side.Scattering of incident light from outside by the wiring and hencelowering in visibility can be prevented.

FIG. 24A shows a structure suitable for the light-emitting element inwhich light emitted from the light-emitting element 309 is radiated tothe side opposite to the substrate. A light shielding layer 2501 isformed on the third inorganic insulating layer 116 and the wirings 121to 125. As the light shielding layer 2501 is formed on the wirings,scattering of incident light from outside by the wirings and hencelowering in visibility can be prevented. FIG. 24B shows a structure inwhich the second organic insulating layer 128 also serves as a lightshielding layer. This structure can provide similar effects.

Any material having insulating and shading properties may be used forforming the light shielding layer. For example, an insulating organiccompound mixed with black or similar pigments may be used. To color theorganic compound, fine powder of carbon may be mixed.

These structures of this example can be freely combined with Examples 1to 3.

Example 9

In this example, FIGS. 25A and 25B and FIGS. 26A and 26B show exemplarymodes having different structures of the pixel part from that ofExample 1. First, the layers up to the third inorganic insulating layer116 are formed similarly to Example 1. Then, a contact hole is formedand the wiring 123 is formed. After that, in order to form the anodelayer, an oxide conductive film with a work function of 4 eV or moresuch as ITO is formed. The anode layer 126 is formed to superimpose onthe wiring 123.

In FIG. 25A, the second organic insulating layer 128 covering an endpart of the anode layer 126 is formed using a photosensitivenegative-type organic resin. For example, a photosensitive negative-typeacrylic resin is used. Thus, the end part where the second organicinsulating layer 128 contacts the anode layer 126 has an inclinedsurface having curvatures as shown in FIG. 25A, and its shape can beexpressed by at least two curvatures R1, R2. The center point of R1 isabove the wiring and the center point of R2 is below the wiring.Although this shape slightly varies depending on exposure conditions,the thickness is 1.5 μm and R1, R2 have values of 0.2 to 2 μm. In anycase, an inclined surface having continuously changing curvatures isformed.

After that, the fourth inorganic insulating layer 129, the organiccompound layer 130, the cathode layer 131 and the fifth insulating layer132 are formed along this inclined surface having the smooth curvatures,as shown in FIG. 25B. The cross-sectional shape of the second organicinsulating layer 128 has an effect of relaxing the stress (particularlyin a region where the anode layer 126, the fourth inorganic insulatinglayer 129 and the organic compound layer 130 are overlapped, asindicated by a dotted line in FIG. 25B). This enables restraint ofdegradation of the light-emitting element from this end part. That is,progressive degradation which starts at the periphery of the pixel andexpands a non-light-emitting region can be restrained.

FIG. 26A shows an example in which the second organic insulating layer128 is formed using a photosensitive positive-type acrylic resin insteadof the photosensitive negative-type acrylic resin. In this case, the endpart has a different cross-sectional shape. A radius of curvature R3 of0.2 to 2 is provided and its center point is situated below the anodelayer 126. After this layer is formed, the fourth inorganic insulatinglayer 129, the organic compound layer 130, the cathode layer 131 and thefifth insulating layer 132 are formed along the inclined surface havingthe curvature, as shown in FIG. 26B. In this case, too, similar effectscan be provided.

This example can be carried out by particularly replacing the secondorganic insulating layer of Examples 1, 2, 3 and 8.

Example 10

In Example 1, the structure of the organic compound layer in thelight-emitting element 309 is not particularly limited and any knownstructure can be used. The organic compound layer 130 includes alight-emitting layer, a hole injection layer, an electron injectionlayer, a hole transport layer, an electron transport layer and the like.The organic compound layer 130 can take a form in which these layers arestacked or a form in which a part or all of the materials forming theselayers are mixed. Specifically, it includes a light-emitting layer, ahole injection layer, an electron injection layer, a hole transportlayer, an electron transport layer and the like. An EL element basicallyhas a structure in which an anode, a light-emitting layer and a cathodeare sequentially stacked. In addition to this structure, the EL elementmay also have a structure in which an anode, a hole injection layer, alight-emitting layer and a cathode are sequentially stacked or in whichan anode, a hole injection layer, a light-emitting layer, an electrontransport layer, a cathode and the like are sequentially stacked.

The light-emitting layer is typically made of an organic compound.However, the light-emitting layer may be made of a charge injection andtransport material and a light-emitting material containing an organiccompound or inorganic compound, and may include one type or a pluralityof types of layers selected from a low-molecular organic compound, amedium-molecular organic compound and a high-molecular organic compoundin accordance with the number of molecules, in combination with aninorganic compound having electron injection and transport properties orhole injection and transport properties. The medium-molecular organiccompound is an organic compound which does not sublimate and in whichthe number of molecules is 20 or less or the length of chained moleculesis 10 μm or less.

For the light-emitting material, metal complexes such astris-8-quinolinolatoaluminum complex and bis(benzoquinolite) berylliumcomplex as well as phenylanthracene derivative, tetraaryldiaminederivative, distyrylebenzene derivative and the like can be used aslow-molecule organic compounds. Using these as host materials, coumarinderivative, DCM, quinacridone, rubrene and the like can be used. Otherknown materials can also be used. High-molecule organic compoundsinclude poly[p-phenylene vinylene]-based, poly[p-phenylene]-based,polythiophene-based, polyfluorene-based materials and the like.Poly(p-phenylene vinylene) (PPV), poly(2,5-dialkoxy-1,4-phenylenevinylene) (RO-PPV), poly[2-(2′-ethylhexoxy)-5-methoxy-1,4-phenylenevinylene] (MEH-PPV), poly[2-(dialkoxyphenyl)-1,4-phenylene vinylene](ROPh-PPV), poly[p-phenylene] (PPP), poly(2,5-dialkoxy-1,4-phenylene)(RO-PPP), poly(2,5-dihexoxy-1,4-phenylene), polythiophene (PT),poly(3-alkylthiophene) (PAT), poly(3-hexylthiophene) (PHT),poly(3-cyclohexylthiophene) (PCHT), poly(3-cyclohexyl-4-methylthiophone)(PCHMT), poly(3,4-dicyclohexylthiophene) (PDCHT),poly[3-(4-octylphenyl)-thiophene] (POPT),poly[3-(4-octylphenyl)-2,2-bithiophene] (PTOPT), polyfluorene (PF),poly(9,9-dialkylfluorene) (PDAF), poly(9,9-dioctylfluorene) (PDOF) andthe like may be used.

An inorganic compound material may be used for the charge injection andtransport layer. The inorganic compound material may be diamond-likecarbon (DLC), Si, Ge, or oxide or nitride thereof, which may be properlydoped with P, B, N or the like. It may also be oxide, nitride orfluoride of an alkaline metal or alkaline-earth metal, or a compound oralloy including that metal and at least one of Zn, Sn, V, Ru, Sm or In.

The above-described materials are just examples. By properly stackingfunction layers such as a bole injection and transport layer, a holetransport layer, an electron injection and transport layer, an electrontransport layer, a light-emitting layer, an electron block layer, a boleblock layer and the like using these materials, the light-emittingelement can be formed. A mixed layer or a mixed junction made of acombination of these layers may be formed. Electroluminescence includeslight emission in the case where a ground state is restored from asinglet excited state (fluorescence) and light emission in the casewhere a ground state is restored from a triplet excited state(phosphorescence). The electroluminescence device according to thepresent invention may use one of these light emissions or may use bothlight emissions.

This example can be carried out by particularly replacing thelight-emitting device 309 of Examples 1, 2, 3 and 8.

Example 11

The anode layer 126 and the cathode layer 131 of the light-emittingelement 309 in Example 1 can be reversed. In this case, the layers arestacked in the order of the cathode layer 131, the organic compoundlayer 130 and the anode layer 126. As the anode layer 126, a nitridemetal (for example, titanium nitride) having a work function of 4 eV ormore as well as ITO is formed with a thickness of 10 to 30 nm, thusproviding light transmittance. As the structure of the cathode layer131, a lithium fluoride layer with a thickness of 0.5 to 5 nm may beformed on an aluminum layer with a thickness of 10 to 30 nm.

This example can be carried out by particularly replacing thelight-emitting element 309 of Examples 1, 2, 3 and 8.

Example 12

The present invention is capable of various applications. A portableinformation terminal (personal digital assistants, mobile computers,mobile phones and the like), a video camera, a digital camera, apersonal computer, a television receiver, a mobile phone can be suchexamples. FIG. 22 will show some of these examples.

A television receiver completed by applying the invention is exemplifiedin FIG. 22A, the television receiver includes a housing 3001, a support3002, a display 3003 and the like. The TFT substrate manufacturedaccording to the invention is adopted in the display 3003 to completethe television receiver.

A video camera completed by applying the invention is exemplified inFIG. 22B, the video camera includes a body 3011, a display 3012, a soundinput 3013, an operating switch 3014, a battery 3015, an image receivingsection 3016 and the like. The TFT substrate manufactured according tothe invention is adopted in the display 3012 to complete the videocamera.

A laptop completed by applying the invention is exemplified in FIG. 22C,the laptop includes a body 3021, a housing 3022, a display 3023, akeyboard 3024 and the like. The TFT substrate manufactured according tothe invention is adopted in the display 3023 to complete the laptop.

A PDA (personal digital assistant) completed by applying the inventionis exemplified in FIG. 22D, the PDA includes a body 3031, a stylus 3032,a display 3033, an operating button 3034, an external interface 3035 andthe like. The TFT substrate manufactured according to the invention isadopted in the display 3033 to complete the PDA.

A sonic reproducer completed by applying the invention is exemplified inFIG. 22E, in specific, it is a car audio apparatus including a body3041, a display 3042 and operating switches 3043 and 3044. The TFTsubstrate manufactured according to the invention is adopted in thedisplay 3042 to complete the car audio system.

A digital camera completed by applying the invention is exemplified inFIG. 22F, the digital camera includes a body 3051, a display (A) 3052,an eyepiece 3053, an operating switch 3054, a display (B) 3055 and abattery 3056. The TFT substrates manufactured according to the inventionare adopted to the displays (A) 3052 and (B) 3055 to complete thedigital camera.

A mobile phone completed by applying the invention is exemplified inFIG. 22G, the mobile phone includes a body 3061, a voice output section3062, a voice input section 3063, a display 3064, an operating switch3065 and an antenna 3066. The TFT substrate manufactured according tothe invention is adopted to the display 3064 to complete the mobiletelephone.

In addition, the application of the invention includes, but is notlimited the apparatuses shown in this figure.

As is described above, according to the present invention, a shieldpattern made of metal wiring is formed in an outer peripheral part of adisplay region formed by a light-emitting element, and a recessed andprotruding shape is formed over the shield pattern by an organicinsulating layer and an inorganic insulating layer covering the surfaceof the organic insulating layer. Then, an adhesive resin is filled inthis region to form a seal pattern. Thus, a rigid sealing structure witha high adhesive strength can be formed. By forming such a sealingstructure, entry of moisture or the like from outside can be prevented.Thus, degradation of the light-emitting device is prevented to enableimprovement in reliability of the light-emitting device.

Moreover, in the internal structure, a semiconductor film, a gateinsulating film and a gate electrode as principal constituent elementsof a TFT are surrounded from over and below by an inorganic insulatingmaterial selected from silicon nitride, silicon oxynitride, aluminumoxynitride, aluminum oxide, and aluminum nitride. Thus, a structure toprevent contamination due to alkaline metals and organic materials isprovided. Meanwhile, the light-emitting element partly contains analkaline metal and is surrounded by an inorganic insulating materialselected from silicon nitride, silicon oxynitride, aluminum oxynitride,aluminum nitride, and DLC, thus realizing a structure to preventpenetration by oxygen and moisture from outside. The reliability of thelight-emitting device can be improved.

1. A light-emitting device comprising: a first substrate; a firstinsulating layer over the first substrate; a display region including alight-emitting element over the first insulating layer; a first metallayer and a second metal layer over the first insulating layer; a secondinsulating layer over the first insulating layer, the second insulatinglayer including a first aperture over the first metal layer and a secondaperture over the second metal layer; a resin layer over the secondinsulating layer, in the first aperture and the second aperture; and asecond substrate over the resin layer, wherein the first metal layer andthe second metal layer surround the display region, and wherein thefirst substrate is fixed to the second substrate with the resin layerinterposed therebetween.
 2. The light-emitting device according to claim1, wherein the first insulating layer includes an inorganic material. 3.The light-emitting device according to claim 2, wherein the inorganicmaterial is silicon nitride.
 4. The light-emitting device according toclaim 1, wherein the second insulating layer is an organic insulatinglayer.
 5. The light-emitting device according to claim 1, wherein eachof the first metal layer and the second metal layer is a continuouslinear patterned layer.
 6. The light-emitting device according to claim1, wherein each of the first metal layer and the second metal layer is adiscontinuous dotted-line patterned layer.
 7. A light-emitting devicecomprising: a first substrate; a first insulating layer over the firstsubstrate; a second insulating layer over the first insulating layer; adisplay region including a light-emitting element over the secondinsulating layer; a first metal layer and a second metal layer over thesecond insulating layer; a third insulating layer over the secondinsulating layer, the third insulating layer including a first apertureover the first metal layer and a second aperture over the second metallayer; a resin layer over the third insulating layer, in the firstaperture and the second aperture; and a second substrate over the resinlayer, wherein the first metal layer and the second metal layer surroundthe display region, and wherein the first substrate is fixed to thesecond substrate with the resin layer interposed therebetween.
 8. Thelight-emitting device according to claim 7, wherein the first insulatinglayer includes an organic compound.
 9. The light-emitting deviceaccording to claim 7, wherein the second insulating layer includes aninorganic material.
 10. The light-emitting device according to claim 9,wherein the inorganic material is silicon nitride.
 11. Thelight-emitting device according to claim 7, wherein the third insulatinglayer is an organic insulating layer.
 12. The light-emitting deviceaccording to claim 7, wherein each of the first metal layer and thesecond metal layer is a continuous linear patterned layer.
 13. Thelight-emitting device according to claim 7, wherein each of the firstmetal layer and the second metal layer is a discontinuous dotted-linepatterned layer.
 14. A light-emitting device comprising: a firstsubstrate; a first insulating layer over the first substrate; a displayregion including a light-emitting element over the first insulatinglayer; a first metal layer and a second metal layer over the firstinsulating layer; a second insulating layer over the first insulatinglayer, the second insulating layer including a first aperture over thefirst metal layer and a second aperture over the second metal layer; aresin layer over the second insulating layer, in the first aperture andthe second aperture; and a second substrate over the resin layer,wherein the first metal layer and the second metal layer surround thedisplay region, wherein the first substrate is fixed to the secondsubstrate with the resin layer interposed therebetween, and wherein thesecond insulating layer covers a side surface of the first insulatinglayer.
 15. The light-emitting device according to claim 14, wherein thefirst insulating layer includes an inorganic material.
 16. Thelight-emitting device according to claim 15, wherein the inorganicmaterial is silicon nitride.
 17. The light-emitting device according toclaim 14, wherein the second insulating layer is an organic insulatinglayer.
 18. The light-emitting device according to claim 14, wherein eachof the first metal layer and the second metal layer is a continuouslinear patterned layer.
 19. The light-emitting device according to claim14, wherein each of the first metal layer and the second metal layer isa discontinuous dotted-line patterned layer.
 20. A light-emitting devicecomprising: a first substrate; a first insulating layer over the firstsubstrate; a second insulating layer over the first insulating layer; adisplay region including a light-emitting element over the secondinsulating layer; a first metal layer and a second metal layer over thesecond insulating layer; a third insulating layer over the secondinsulating layer, the third insulating layer including a first apertureover the first metal layer and a second aperture over the second metallayer; a resin layer over the third insulating layer, in the firstaperture and the second aperture; and a second substrate over the resinlayer, wherein the first metal layer and the second metal layer surroundthe display region, wherein the first substrate is fixed to the secondsubstrate with the resin layer interposed therebetween, and wherein thethird insulating layer covers a side surface of the first insulatinglayer and a side surface of the second insulating layer.
 21. Thelight-emitting device according to claim 20, wherein the firstinsulating layer includes an organic compound.
 22. The light-emittingdevice according to claim 20, wherein the second insulating layerincludes an inorganic material.
 23. The light-emitting device accordingto claim 22, wherein the inorganic material is silicon nitride.
 24. Thelight-emitting device according to claim 20, wherein the thirdinsulating layer is an organic insulating layer.
 25. The light-emittingdevice according to claim 20, wherein each of the first metal layer andthe second metal layer is a continuous linear patterned layer.
 26. Thelight-emitting device according to claim 20, wherein each of the firstmetal layer and the second metal layer is a discontinuous dotted-linepatterned layer.
 27. A light-emitting device comprising: a firstsubstrate; a conductive layer over the first substrate; a firstinsulating layer over the first substrate and the conductive layer; adisplay region including a light-emitting element over the firstinsulating layer; a first metal layer and a second metal layer over thefirst insulating layer; a second insulating layer over the firstinsulating layer, the second insulating layer including a first apertureover the first metal layer and a second aperture over the second metallayer; a resin layer over the second insulating layer, in the firstaperture and the second aperture; and a second substrate over the resinlayer, wherein the first metal layer and the second metal layer surroundthe display region, wherein the first substrate is fixed to the secondsubstrate with the resin layer interposed therebetween, wherein thesecond insulating layer covers a side surface of the first insulatinglayer, and wherein one of the first metal layer and the second metallayer is connected to the conductive layer.
 28. The light-emittingdevice according to claim 27, wherein the first insulating layerincludes an inorganic material.
 29. The light-emitting device accordingto claim 28, wherein the inorganic material is silicon nitride.
 30. Thelight-emitting device according to claim 27, wherein the secondinsulating layer is an organic insulating layer.
 31. The light-emittingdevice according to claim 27, wherein each of the first metal layer andthe second metal layer is a continuous linear patterned layer.
 32. Thelight-emitting device according to claim 27, wherein each of the firstmetal layer and the second metal layer is a discontinuous dotted-linepatterned layer.
 33. A light-emitting device comprising: a firstsubstrate; a conductive layer over the first substrate; a firstinsulating layer over the first substrate and the conductive layer; asecond insulating layer over the first insulating layer; a displayregion including a light-emitting element over the second insulatinglayer; a first metal layer and a second metal layer over the secondinsulating layer; a third insulating layer over the second insulatinglayer, the third insulating layer including a first aperture over thefirst metal layer and a second aperture over the second metal layer; aresin layer over the third insulating layer, in the first aperture andthe second aperture; and a second substrate over the resin layer,wherein the first metal layer and the second metal layer surround thedisplay region, wherein the first substrate is fixed to the secondsubstrate with the resin layer interposed therebetween, wherein thethird insulating layer covers a side surface of the first insulatinglayer and a side surface of the second insulating layer, and wherein oneof the first metal layer and the second metal layer is connected to theconductive layer.
 34. The light-emitting device according to claim 33,wherein the first insulating layer includes an organic compound.
 35. Thelight-emitting device according to claim 33, wherein the secondinsulating layer includes an inorganic material.
 36. The light-emittingdevice according to claim 35, wherein the inorganic material is siliconnitride.
 37. The light-emitting device according to claim 33, whereinthe third insulating layer is an organic insulating layer.
 38. Thelight-emitting device according to claim 33, wherein each of the firstmetal layer and the second metal layer is a continuous linear patternedlayer.
 39. The light-emitting device according to claim 33, wherein eachof the first metal layer and the second metal layer is a discontinuousdotted-line patterned layer.